Bodywork dent repair tool with pdr method

ABSTRACT

A tool for repairing dents in a car body using the PDR method, containing at least an interchangeable working tip (1)—round, conical or flat, octagonal nipple (2) and handle (3), significant by the construction of a replaceable handle (3), especially for tips (3) with a diameter of 0.3 cm to 0.7 cm, and a removable, working tip (1), permanently attached to a sleeve (4) and a nipple (2), whereas the tip (1) being knurled on the side the base of the tip (6) at a length of 1 cm and at the end of the base of the tip (6) a sleeve (4) is mounted with a hole with a diameter drilled inside out corresponding to the diameter of the tip (1), clamped with a punch (7) at the base of the tip (6).

This application is a nonprovisional application which claims a priorityof Polish patent application no.: P.439363, filed on Oct. 29, 2021, thecontent of which is hereby incorporated by reference.

The subject of the invention is a tool for repairing dents in a car bodyusing the PDR method (Paintless Dent Removal), applicable in theautomotive industry, especially in bodyshops.

PDR is a popular method of repairing dents without painting. It consistsin pushing out or pulling out small dents. Removing dents withoutpainting is made with the use of a special, professional glue. By usingthis glue and the picks (hooks) the dents are “pulled out”. This way isused in the case of elements that are difficult to access, because itdoes not require the disassembly of individual car parts, including theremoval of roof lining, when a dent was formed on the roof by hail. Thesecond method on repairing dents without painting is pushing them out.This PDR technique works best when the dent cannot be reached from theinside, especially in the case of the tailgate (trunk lid), doors orfenders. The dent is pushed out with the use of specialized tools,which, due to the type of damage, may differ in the length, thicknessand shape of tags. Their selection depends on both the shape of a dentand its location.

Some PDR tools have replaceable screw-in tags (steel or made of plastic)in the form of balls, cones or tips. Depending on the type, there aredevices with different shapes of the fin and flag. Some models areequipped with a regulated, adjustable handle, which facilitates theimplementation of repairs. When working on body parts withoutreinforcements, tools are used which work on the principle of a leverand require appropriate support in the form a suspended ring or chain.To remove dents in reinforcement places are used fin tools, insertedbetween the reinforcement and the outer sheathing of a vehicle. In thiscase, it is possible to repair parts that do not have technologicalholes allowing the insertion of a tool. Fins give the ability to gounder the reinforcement directly at the dent and work on the principleof twisting. There are known PDR door tools which enable to remove dentsin an outer door sheathing, front and rear fenders. They are insertedbetween the window reinforced with a plastic cover and the bodyworksheathing tilted with a wedge and also work by twisting.

Technologically, we also know PDR tools: with a replaceable or fixedtip, with a length from approx. 13 cm to 187 cm, with a cross-sectionaldiameter of approx. 0.3 cm to 4 cm, from no bends (folds) up to 3 bends,with an exchangeable or fixed handle, with a curved, conical or flattip.

From current state of technology, we also know the dent removal toolaccording to the invention U.S. Pat. No. 9,868,143B2, which includes aremovable end tip, conduit assembly and a handle. The conduit assemblyincludes many conduit segments of varying lengths that are detachableand replaceable. The length of the conduit assembly can be adjusted byjoining one or more different lengths of conduit together. Depending onthe type of dent to be repaired, one or more different types of tips maybe attached to the conduit assembly. One type of head includes a T-barwith two ends, each end configured for attachment to one of a number ofdifferent types of tips.

The American patent description US2005252271A1 discloses a toolkit forthe PDR process designed to remove a certain class of dents in panels ofa car body that is modified to have removable handles (grips) withdifferent positions relative to the working end of the tool. In thisway, it is allowed for the modified toolkit to consist of a much smallernumber of individual tools.

Tools for PDR processes with interchangeable handles and adjustable fortips with a diameter of more than 0.6 cm are also known in the state oftechnology.

The solutions known in the state of technology have an exchangeable andadjustable handle only for tips with a cross-sectional diameter from 0.8cm upwards, which results from the used technology of metalworkingprocesses for the production of thin PDR tool tips in the form of hooksand other shapes with a cross-sectional diameter of 0.3 cm to 0.7 cm,and also from the fact that any thermal interference in these smallsections causes changes in the parameters of steel, and hence thedeformation of the tool tips, what is a significant inconvenience duringPDR repairs. In the state of technology, the tools with thinner sectionshave fixed handles that extend tips and bend in the form of a handle,often coated with various types of resins and plastics.

There are also metal handles used, and therefore they are slippery tothe touch, which is an inconvenience in case of their use during PDRrepairs. These handles are too short at the point of gripping whattranslates into the need for more force by an operator of the tool whenusing longer tips and balancing through it with the whole body. Inaddition, the tip fits very shallowly into the nipple of the handle,which often leads to the breaking of a nipple after using the tool forsome time.

The invention overcomes the above-mentioned disadvantages. The purposeof the invention was to construct a universal tool for PDR repairs bydeveloping such a handle and fixing the tips in the handle to—regardlessof the tool tip diameter and shape used by an operator—operate it byone, universal and adjustable handle. Moreover, the specificity of theinvention lies in the fact that, as a result of the use of those alreadyknown PDR tool manufacturing processes, the tool maintains PDRparameters desired by an operator such as malleability, resilience,flexibility and durability necessary for this type of repairs. What ismore, the solution according to the invention makes it possible tomaintain the properties spring steel used to make its tips and maintainthe desired parameters for the tool during operation. The use of theinvention also allows to limit the PDR toolkit by using one universaland adjustable handle.

The essence of the invention is a tool for repairing dents in the carbody using the PDR method, containing at least an exchangeable workingoval, conical or flat tip, octagonal nipple and handle, characterized bythe fact that it is made of an interchangeable handle, especially fortips with a diameter of 0.3 cm to 0.7 cm, and a replaceable working tip,permanently joined with the sleeve (tube) and nipple, whereas the tipbeing knurled at the base of the tip at the length of 1 cm, and at theend of the tip base there is a sleeve (tube) with a hole drilled insideout with a diameter corresponding to the diameter of the tip, clampedwith a punch on the base of the tip, at the same time, the tip with thesleeve clamped on it is pressed into the octagonal nipple for a lengthof 1 cm and welded with a thin weld, and the handle is equipped with anoctagonal slot in which a nipple latch is mounted detachably by means ofa spring ball.

Preferably, the tip is made of a non-weldable alloy.

Preferably, the sleeve (tube) is made of a soft weldable alloy.

Preferably, the spring ball is made of a steel spring increased by forceD=M06, L=14.

Preferably, the tip with a cross-sectional diameter of 0.3 cm and 0.4 cmis knurled by rollers with a stroke of 1.2 mm.

Preferably, the tip with a cross-sectional diameter of 0.5 cm, 0.6 cmand 0.7 cm is knurled by rollers with a stroke of 1.6 mm.

Preferably, the tip, sleeve and nipple are tempered martensitically andthen oxidised in a chemical bath or technically chrome-plated.

Preferably, the longitudinal handle is connected separately to thenipple by means of a spring ball screwed in the slot perpendicularly tothe guiding of a working tip.

Preferably, the transverse handle is connected separately to the nippleby means of a spring ball screwed in the slot mounted transversely tothe surface of the tool grip, however, a bolt made of small diameterwire is placed in the spring ball parallel to the axis of the handle.

Preferably, the handle is equipped with an octagonal slot mounted at theend the handle at right angles to the tool surface grip and transverselyto the length of the handle.

Preferably, the handle is provided with an octagonal slot which ismounted at bored and milled head screwed in the handle from the facetransversely to the length of the handle, using a threaded screw with adrilled and threaded hole under the snap-on locking spring ball.

In an example of the invention, a car body dent repair tool with the PDRmethod includes an exchangeable working tip (1), round, conical or flat,octagonal nipple (2) and handle (3), as well as replaceable handle (3),especially for the tips (3) with a cross-sectional diameter of 0.3 cm to0.7 cm. The replaceable working tip (1) is permanently connected withthe sleeve (tube) (4) and the nipple (2), whereas the tip (1) is knurledfrom the base of the tip (6) at a length of 1 cm, and at the end of thebase of the tip (6) there is a sleeve (4) with a hole drilled inside outwith a diameter corresponding to that of the tip (1), which is clampedwith a punch (7) at the base of the tip (6). At the same time, the tip(1) with a sleeve clamped on it (4) is pressed into the octagonal nipple(2) by a length of 1 cm and welded to it with a thin welding (14).Moreover, the handle (3) is equipped with an octagonal slot (8) in whicha snap nipple (2) is detachably fastened with a spring ball (9).

The tip (1) is made of a non-weldable alloy. The sleeve (4) is made ofsoft weldable alloy. The spring ball (9) is made of steel increasedspring with the force D=M06, L=14.

Moreover, the tip (1) with a diameter of 0.3 cm and 0.4 cm is knurled bysteel rollers with a stroke of 1.2 mm, and the tip (1) with across-sectional diameter of 0.5 cm, 0.6 cm and 0.7 cm knurled withrollers with a stroke of 1.6 mm.

In this example, the tip (1), sleeve (4) and nipple (2) are hardenedmartensitically and then oxidized in a chemical bath or technicallychrome-plated.

Moreover, in this example, a combined handle (3) longitudinal (15) isused, separately connected with a nipple (3) by means of a spring ball(9) screwed in the slot (8) perpendicular to the guiding of a workingtip.

In other cases of the invention creation, other types of handle havebeen used (3).

The transverse handle (3) (16) is separately connected to the nipple (2)by means of a spring ball (9) screwed in the slot (8) mountedtransversely to the surface of the tool grip, whereas a bolt made ofsmall diameter wire is placed in the spring ball parallel to the axis ofthe handle.

Another example depicts a handle (3), “large” (17) provided withoctagonal slot (8) mounted at the end of the handle (3) at right anglesto the surface of the tool grip and transversely to the length of thehandle (3).

In another example, the “handle (3), small” (18) is equipped with anoctagonal slot (8), which is mounted in a turned and milled head (11)screwed into the handle (3) from the front side transversely to thelength of the handle (3), using a threaded screw (12) with a drilled andthreaded hole (13) for a locking snap-on spring ball (9).

Depending on the application, the examples of the invention may vary asfor the shape, length and diameter of the section of the tip (1), shapeand size of the handle (3).

The subject of the invention in its exemplary embodiments is shown inthe drawing, whereas:

FIG. 1 shows a front rectangular view of the tool;

FIG. 2 shows a front view of the tool without handle with the tipseparated (1), sleeve (4) and nipple (2);

FIG. 3 shows the cross-sections and 45-degree views of the sleeve (4) ofdifferent diameters from 0.4 cm to 0.7 cm;

FIG. 4 shows a cross-section of the nipple (2);

FIG. 5 shows a view of the handle (3) at an angle of 45 degrees;

FIG. 6 shows a front perpendicular view of the longitudinal handle (3);

FIG. 7 shows a front view of the transverse handle (3);

FIG. 8 shows a front view of the “big” handle (3) (17);

FIG. 9 shows a side view of the “small” handle (3);

FIG. 10 shows a front view of a turned and milled head (11) metal to the“small” handle (3) (18), with a threaded welded screw (12) in order toscrew in the head into the handle body; with drilled and threaded hole(13) under the snap-on locking ball (9).

The invention will find its industrial application in the automotiveindustry, especially in bodyshops.

1. A tool for repairing dents in a car body using a PDR method,comprising at least an interchangeable working tip (1) having round,conical or flat shape, an octagonal nipple (2), and a replaceable handle(3) for the interchangeable tips (1) with a diameter of 0.3 cm to 0.7cm, wherein the interchangeable, working tip (1), is attached to asleeve (4) and the nipple (2), wherein the nipple (2) is permanentlyattached to the replaceable handle (3), wherein the tip (1) is knurledfrom the side of a base (6) of the tip (1) at a length of 1 cm, whereinat the end of the base (6) of the tip the sleeve (4) is mounted with ahole with a diameter corresponding to a diameter of the tip (1), clampedwith a punch (7) at the base (6) of the tip (1), wherein at the sametime the tip (1), with the sleeve (4) clamped on the tip, is pressedinto the octagonal nipple (2) by a length of 1 cm and welded to thenipple (2) with a thin weld (14), and wherein the handle (3) is equippedwith an octagonal slot (8) in which the nipple (2) is detachablyattached by a spring ball (9) as a snap-on connection.
 2. The toolaccording to claim 1, wherein the tip (1) is made of a non-weldablealloy.
 3. The tool according to claim 1, wherein the sleeve (4) is madeof a soft weldable alloy.
 4. The tool according to claim 1, wherein thespring ball (9) is made of a steel spring with the force D=M06, L=14. 5.The tool according to claim 1, wherein the tip (1) with across-sectional diameter of 0.3 cm and 0.4 cm is knurled with rollerswith a stroke of 1.2 mm.
 6. The tool according to claim 1, wherein thetip (1) with a cross-sectional diameter of 0.5 cm, 0.6 cm or 0.7 cm isknurled with rollers with a stroke of 1.6 mm
 7. The tool according toclaim 1, wherein the tip(1), sleeve (4) and nipple (2) aremartensitically hardened and then oxidized in a bath chemicallychrome-plated.
 8. The tool according to claim 1, wherein a longitudinalhandle (3) (15) is separately connected to the nipple (2) with thespring ball (9) screwed into the slot (8) perpendicularly to a guidingof a working tip (1).
 9. The tool according to claim 1, wherein atransverse handle (3) (16) is separately connected to the nipple (2)with the spring ball (9) screwed into the slot (8) mounted transverselyto the surface of a tool grip, whereas in the spring ball (9) ispositioned parallel to an axis of the handle (3) a bolt (10) made of asmall diameter wire.
 10. The tool according to claim 1, wherein a handle(3) (17) is equipped with the octagonal slot (8) which is mounted at theend of the handle (3) at an angle straight to the surface of a tool gripand transversely to the length of the handle (3).
 11. The tool accordingto claim 1, wherein a handle (3) (18) is equipped with the octagonalslot (8) which is mounted in a threaded and milled head (11) screwedinto the handle (3) from the face transversely to the length of thehandle (3) by means of a threaded bolt (12) with a drilled and threadedhole (13) under a snap-on locking spring ball (9).